CFMoto UTV Terracross CF625-3, CF500-6, CF625-6. Service Manual - part 7

-95-

Filter Systems
Air Filter

 

Always change the air filter at the intervals outlined in the Periodic

      

Maintenance Chart beginning on page 72

.

■

Methods to clean or replace air filter element 

(

see

 

picture

 2) 

●

Loosen fix clip 3, remove air filter element cap 2

; 

●

Loosen screw 4, take down air filter element assy 5

;

●

Take out air filter element 6

;

●

Clean filter element 6 dust and oil stains with cleaner, dry out, soak filter

 

element

 

6 in

 

engine

 

oil

, 

dry

 

it

 

properly

; 

replace

 

the

 

filter

 

element

 

if

 

it

 

damaged

; 

reinstall filter element 6 and fix it into filter case 1

;

●

tighten screw 4 in

 

turn

, 

coat

 

filter

 

element

 

cover 2, clamping clip 3.

Do

 

not

 

clean

 

the

 

air

 

filter

 

element

 

with

 

gas

 

or

 

low

 

flash

 

point

 

solvents

.

●

If the owner use different air filter from this owner

'

s manual, 

first

 

the

 

filter

 

must

 

be

 

familiar

 

with

 

the

 

engine

'

s performance, so that 

secure the engine performance, or else, the owner will be responsible for the
engine damage caused by improper filter

, 

also

 

the

 

owner

 

is

 

responsible

 

for

 

the filter cleaning, maintenance etc.

   

Attention!

 

Cleaning

 

the

 

air

 

filter

 

elements

 

and

 

inner

 

dirty

 

per

 

100

 

hours.

 

Shorten

 

this

 

cycle

 

when

 

the

 

filter

 

working

 

in

 

dusty

 

and

 

moisture

 

conditions

. 

The

 

filter

 

element

 

too

 

dirty

 

or

 

improper

 

installment

 

may

 

shorten

 

the

 

engine

 

lifetime

.

-96-

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor

, 

could result in serious injury or death.

Do not perform clean-out immediately after the engine has been run, as the

 

exhaust system becomes very-

 hot. Serious burns could result from contact

 

with the exhaust components. Allow components to cool suffic

iently before

 

proceeding.

Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust contains poisonous

 

carbon monoxide gas that can cause

 loss of consciousness or death in a

 

very short time.

Periodically clean the spark arrestor to remove accumulated carbon.
1

．

Remove the retaining

 

screw and remove the

arrestor 1 from the end of the muffler 4.

2

．

Use a non-synthetic

 

brush to clean the

arrestor screen.

 

A synthetic

brush may melt

 

if components are

 

warm.

NOTE: If necessary, blow

 

debris from the

screen with compressed

 

air.

3

．

Inspect the screen for

 

wear and damage.

 

Replace a worn or

damaged screen.

4．Reinstall the arrestor. Torque screws 3 to: 
6-8 ft.lbs（8-10Nm）

-97-

Failure to check or maintain proper operation of the throttle system can result
in an accident and lead to serious injury or death if the throttle pedal sticks

 

during operation.

Never start or operate this vehicle if it has a sticking or improperly operating

 

throttle pedal.

Immediately contact your dealer for service if throttle problems arise.
Always check the pedal for free movement and return before starting the

 

engine and occasionally during 

operation.

Throttle Freeplay

 

If the throttle pedal has excessive

 

play due to cable stretch or misadjustment,

it will cause a delay

 

in throttle response, especially at

low engine speed.The throttle

 

may also not open fully. If the

throttle pedal has no freeplay, the

 

throttle may be hard to 

control,and the idle speed may be erratic.

 

Check the throttle 

pedal freeplay

 

at the intervals outlined in the

Periodic Maintenance Chart

 

beginning on page 72

. 

Adjust the

 

freeplay if necessary.

Throttle Freeplay Inspection

1

．

Place the transmission in PARK.

2

．

Apply the brakes. Start the engine. Allow it to warm up 

thoroughly.
3

．

Measure the distance the throttle pedal moves before the engine

 

begins to pick up speed. Freeplay

 should be 1/16 to 1/8inches（1.6-3.2mm）

Throttle  

THROTTLE  PEDAL

-98-

Throttle System

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer.

 

If the engine idle speed is not

 

satisfactory, please see your dealer 

for adjustment.

 

Throttle Freeplay Adjustment

1

．

Remove both seats.

 

Remove the rear service

panel. See page 34.
2

．

Locate the throttle cable

 

adjuster.

3

．

Squeeze the end of the rubber

 

boot and slide it far

enough to expose the end

 

of the inline cable adjuster.

4

．

Loosen the adjuster lock

 

nut.

5

．

Rotate the boot to turn the

 

adjuster until 

1/16" to 1/8"（1.6-3.2mm）of freeplay is

achieved at the throttle

 

pedal. See page 97

.

NOTE: 

While adjusting, lightly flip the throttle pedal up and down.

6

．

Tighten the lock nut.

7

．

Squeeze the end of the rubber boot and slide it over the cable

adjuster to its original position

.

THROTTLE  CABLE

SHEATH

LOCK  NUT

ADJUST  NUT

-99-

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the
brake pedal. See page 43

.

Always check brake pedal travel and the brake fluid reservoir level
before each use of the vehicle.
When applied, the brake pedal should
feel firm.

 

Any sponginess would indicate a possible fluid leak or low

brake fluid level, which must be corrected before riding.

 

See page 100
for brake fluid information.
If you discover any irregularities in brake system operation, including
excessive pedal travel, contact your dealer for proper diagnosis and

 

repairs.

Operating the vehicle with a spongy brake pedal can result in loss of braking,
which could cause an accident resulting in severe injury or death. Never
operate the vehicle with a spongy-feeling brake pedal.

-100-

Brakes

Brake Fluid

Inspect the level of the brake fluid before each operation. If the fluid

 

level is low add DOT 4 brake fluid only.

 

Change the brake fluid every two

 

years and any time the fluid

 

becomes contaminated, the fluid

 

level is below

 the minimum, or if

 

the type and brand of the

 

fluid

 

in

 

the reservoir are unknown.

 

Access the brake fluid

 reservoir
through the left front wheel well.
1

．

Position the vehicle on a

 

level surface.

2

．

Place the transmission in

 

PARK.

 

3

．

View the brake fluid level in

 

the reservoir. The level

 

should be between the maximum

 

and minimum level

 

lines.

4

．

If the fluid level is lower

 

than the lower level line, add

 

brake

 

fluid

 

to

 

the

 

upper

 

line

.

5

．

Apply the brake forcefully for a few seconds and check for fluid

 

leakage around the fittings.

After opening a bottle of brake fluid, always discard any unused portion.

 

Never store or use a partial

 

bottle

.

 

Brake

 

fluid

 

is

 

hygroscopic

, 

meaning

 

it

 

rapidly absorbs moisture from the air. The moisture causes the boiling

temperature of the brake fluid to drop, which can lead to early brake fade and

 

the possibility of accident or

 severe injury.

-101-

Brake Inspection 

1. Check the brake system for fluid leaks. 
2. Check the brake pedal for excessive travel or a spongy feel. 
3. Check the friction pads for wear, damage and looseness. 
4. Inspect the brake pad wear surface for excessive wear. 
5. Change pads when worn to 3/64" (1 mm

). 

Steering Wheel Inspection 

Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic

 Maintenance Chart beginning on page 74. 

1.  Position the vehicle on level ground. 
2.  Lightly turn the steering wheel left and right. 

3.  There should be 0.8"-1.0" (20-25 mm) of freeplay. 

4.  If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering 
system inspected by an authorized CFMOTO dealer. 

-102-

Suspension Adjustment 

The front and rear suspensions are preload adjustable, with five 
settings on each axle. 

The suspensions are set on the lowest (softest) setting at the factory. This setting is appropriate for nearly

 all riding conditions. Since the vehicle is equipped with full skid plates, suspension adjustment is not
 necessary. 

If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads. Please

 see your CFMOTO dealer for the tool required to make suspension adjustments. Elevate the vehicle slightly 

for easier adjustment. 
Always heed the following rules if you make adjustments to this suspension. 

  

Always

 

return

 

the

 

suspension

 

to

 

the

 

lowest

 (

softest

) 

setting

 

after

 

the

 

load

 

is

 

removed

 

from

 

the

 

vehicle

. 

The

 

increased

 

suspension

 

height

 

will

 

negatively

 

impact

 

vehicle

 

stability

 

when

 

operating

 

without

 

a

 

load

. 

  

Always

 

apply

 

the

 

same

 

adjustment

 

setting

 

to

 

all

 

four

 

wheels

. 

  

Never

 

operate

 

the

 

vehicle on the highest (stiffest) or second highest preload settings without a total

 combined payload 

in the vehicle of 450 lbs

. (

204 kg

) 

or

 

more

. 

Payload

 

includes

 

the

 

driver

, 

passenger

, 

 approved

 

accessories

 

and

 

cargo

. 

Never

 

exceed

 

the

 

stated

 

load

 

capacity for this vehicle. See page 122. 

Adjustment Cam

Highest Setting

Lowest Setting

CFMOTO

OPTIONAL SHOCK ABSORBER ADJUSTMENT(CF625-6)
（FRONT ADJUSTMENT PROCEDURES）

Spring adjustment:
Loosen lock nut (2). Turn adjust nut (3) to proper hardness, and then tighten lock nut (2).

DAMPING RESTORE ADJUSTMENT

Turn adjuster (4) to SLOW side until to end and counter shifts, then turn to FAST side until suitable 
to your comfort.
Damping press adjustment

：

Turn adjuster (1) to HARD side and counter shifts, and then turn to SOFT side until suitable to your 
comfort.

 

②

③

④

After adjustment, keep left and right shock absorber balance.

ATTENTION

-103-

（REAR ADJUSTMENT PROCEDURES）
Spring adjustment

：

Loosen lock nut (3). Turn adjust nut (2) to proper 
hardness, then tighten lock nut (3).
Damping restore adjustment

：

Turn adjuster (1) to SLOW side until to end and 
counter shifts. Then turn to FAST side until suitable to your comfort.
Damping press is not possible to adjust.

After adjustment, keep left and right shock absorber balance.

ATTENTION

-104-

OPTIONAL 2 SHOCK ABSORBER ADJUSTMENT(CF625-6)

Tires

Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, 
which could result in serious injury or death. 
Always replace tires when the tread depth measures 1/8" (3 mm

) 

or

 

less

. 

Improper

 

tire

 

inflation

 

or

 

the

 

use

 

of

 

non

-

standard

 

size

 

or

 

type

 

of

 

tires

 

may

 

adversely

 

affect

 

vehicle

 

handling

, 

which

 

could

 

result

 

in

 

vehicle

 

damage

 

or

 

personal

 

injury

. 

Always

 

maintain proper tire pressure. When replacing tires, always 

use original equipment size and type. 

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8" (3 mm

) 

or

 

less

.

Axle and Wheel Nut Torque Specifications 

Inspect the following items occasionally for tightness, and

 if they've 

been loosened for maintenance service.

Cast  Aluminum

Steel

Wheel Type 

Nut Type 

Location 

Nut Torque

Rim (A luminum) 

Nut 
Nut 

Front and Rear 

75Nm

Front and Rear 

Front and Rear 

75Nm

120Nm

Rim (Steel) 

Any 

Whe el Se at Su pport Re taining Nu t 

NOTE:

 

Do not lubricate the stud or the lug nut

. 

75Nm

75Nm

-105-

Tires

Improperly installed wheels can adversely affect tire wear and vehicle 
handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification.

 Do not service axle nuts that have a cottepin installed. See your dealer.

Wheel Removal

1. Position the vehicle on a level surface.
2. Place the transmission in PARK.Stop the engine.
3. Loosen the wheel nuts slightly.
4. Elevate the side of the vehicle by placing a suitable stand under the 
frame.
5. Remove the wheel nuts and washers.

 

Remove the wheel.

Wheel Installation

1.

 

Place

 

the

 

transmission

 

in

 

PARK

.

2

.

Place the wheel in the correct position on the

wheel hub. Be sure the valve stem

 

is toward the 

outside and rotation arrows on the tire point toward
forward rotation.
3

.

Attach

 

the

 

wheel

 

nuts

 

and

 

washers

 

and

 

finger 

tighten. 
4

.

Carefully

 

lower

 

the

 

vehicle

 

to

 

the

 

ground

. 

5

.

Torque the wheel nuts to specification.

See page 105

. 

Steel rim

Alum allov rim

-106-

Lights

When servicing a halogen lamp, don't touch the lamp with bare fingers. 
Oil from your skin leaves a residue, causing a hot spot that will shorten 
the life of the lamp.

Poor lighting while driving can result in

 

severe

 

injury

 

or

 

death

. 

Headlight

 

and

 

taillight

 

lenses

 

become

 

dirty

 

during

 

normal

 

operation

. 

Wash

 

the

 

headlights

 

frequently

 

to

 

maintain

 

lighting

 

quality

.

Hot

 

comp-

onents

 

can

 

cause

 

serious

 

burns

 

to

 

skin

. 

Do

 

not

 

service

 

the

 

headlamps

 

until

 

they

'

ve

 

cooled

 

sufficiently. 

Headlight Lamp Replacement

1.Unplug the headlamp from 
the wiring harness. Be sure 
to pull on the connector, not 
on the wiring.
2. Turn the lamp counter-
clockwise to remove it.
3. Install the new lamp1

. 

NOTE: Make sure the tab on the lamp locates properly 
in the housing.
4. Reinstall the harness assembly into the head
light assembly.

Tab

Lamp

Bolt

Dust cover

Headlamp rear cover

-107-

Lights 
Headlight Beam Adjustment

1

.

Place

 

the

 

vehicle

 

on

 

a

 

level

 

surface

 

with

 

the

 

headlight

 

approxi

-

mately 25 ft. (7

.6 

m

) 

from

 

a

 

wall

. 

Place

 

the

 

transmission

 

in

 

PARK

. 

2. Measure the distance from the floor to the center of the headlight 
and make a mark on the wall at the same height.
3. Apply the brakes. Start the engine. Turn on the headlights.
4. Observe the headlight aim. The most intense part of the headlight 
beam should be aimed 8" (20 cm) below the mark placed on the 
wall in step 2.
NOTE: Include the weight of a rider on the seat while performing this step. 
5. If adjustment is necessary, turn the headlight adjustment screw to 
adjust the beam.
6. Repeat steps 4-5 until the beam is properly adjusted.

-108-

Lights
Brake Lights 

When the brake pedal is depressed, the brake light comes on. Check the 
brake light before each ride.
1. Turn the ignition switch to the ON position.
2. Apply the brakes. The brake light should come on after about 10 
mm (0.4 in.)

 

of

 

pedal

 

travel

. 

If

 

the

 

light

 

doesn

'

t

 

come

 

on

, 

check

 

the

 

bulb.

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected.

 Take the vehicle to your dealer before starting the engine.

 

If it's impossible to take your vehicle to a dealer before starting it, fol-
low the steps outlined below.

1. Move the vehicle to dry land.
2. Check the air box. If water is present, dry the air box and replace the 
filter with a new filter

. 

Thoroughly

 

dry

 

the

 

air

 

pre

-

filter

. 

See

 

page 100

.

3. Remove the spark plugs.
4. Turn the engine over several times.
5. Dry the spark plugs and reinstall them, or install new plugs.

NOTE:

 Attempt to start the engine. If necessary, repeat the drying procedure.

6. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not.

NOTE: 

If water has been ingested into the PVT follow the procedure on page 

100 for drying.

。

-109-

Battery

Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional
 battery. A sealed battery can be identi fied by its flat covers on the top of the battery. A conventional
 batteryhas six filler caps on the top of the battery.Always keep battery terminals and connections
 free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a
 solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with
 clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow
 cleaning solution or tap water into a conventional battery.

Battery

 

electrolyte

 

is

 

poisonous. It contains sulfuric acid. Serious burns can result from contact with skin,

 eyes or clothing.

Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. 
away. Ventilate when charging or using in an enclosed space. Always shield
eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

-110-